Been running 3-way active up front for a while now, and while I got things EQ'd pretty well, I still know it could sound better. Tweeters flush mounted into the A-pillars and 3.5's in the factory location leave a bit to be desired with staging. I'm also switching to so higher end drivers here soon, so I figured I'd start working on some a-pillar speaker pods to bring them more on axis get the most out of them.
Made a couple templates out of cardboard, traced to MDF, cut out with a saw, smoothed and shaped to better match the contours of the dash, cut the speaker holes, and then duplicated the piece using a router with a flush trim bit. I also made a set out of PVC board, though a bad bearing on one of the bits caused it to melt down into the material in a couple spots. Neither panel is perfect anyway, so I'll be remaking them. I have speaker alignment down, but I'm still experimenting with design. Next set I make I'll be cutting the inside corner after the 3.5" and angling it inwards to lessen the amount of the dash it covers. Once I get a design I'm happy with I'll make a few extra sets before I start fiber-glassing and matching it to the a-pillar. Been going well so far, but this was all a random Monday morning idea, I really have no idea what I'm doing, so I'm bound to have something mess up eventually. Spares are good!